US11441092B2 - Coating solutions, coatings formed therefrom, and coated medical devices - Google Patents
Coating solutions, coatings formed therefrom, and coated medical devices Download PDFInfo
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- US11441092B2 US11441092B2 US15/777,983 US201615777983A US11441092B2 US 11441092 B2 US11441092 B2 US 11441092B2 US 201615777983 A US201615777983 A US 201615777983A US 11441092 B2 US11441092 B2 US 11441092B2
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
- A61L29/00—Materials for catheters, medical tubing, cannulae, or endoscopes or for coating catheters
- A61L29/08—Materials for coatings
- A61L29/085—Macromolecular materials
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
- C10M107/00—Lubricating compositions characterised by the base-material being a macromolecular compound
- C10M107/40—Lubricating compositions characterised by the base-material being a macromolecular compound containing nitrogen
- C10M107/42—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
- A61L29/00—Materials for catheters, medical tubing, cannulae, or endoscopes or for coating catheters
- A61L29/14—Materials characterised by their function or physical properties, e.g. lubricating compositions
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F226/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a single or double bond to nitrogen or by a heterocyclic ring containing nitrogen
- C08F226/06—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a single or double bond to nitrogen or by a heterocyclic ring containing nitrogen by a heterocyclic ring containing nitrogen
- C08F226/10—N-Vinyl-pyrrolidone
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D139/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a single or double bond to nitrogen or by a heterocyclic ring containing nitrogen; Coating compositions based on derivatives of such polymers
- C09D139/04—Homopolymers or copolymers of monomers containing heterocyclic rings having nitrogen as ring member
- C09D139/06—Homopolymers or copolymers of N-vinyl-pyrrolidones
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
- C10M149/00—Lubricating compositions characterised by the additive being a macromolecular compound containing nitrogen
- C10M149/12—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- C10M149/14—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds a condensation reaction being involved
- C10M149/18—Polyamides
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- C—CHEMISTRY; METALLURGY
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- C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
- C10M169/00—Lubricating compositions characterised by containing as components a mixture of at least two types of ingredient selected from base-materials, thickeners or additives, covered by the preceding groups, each of these compounds being essential
- C10M169/04—Mixtures of base-materials and additives
- C10M169/041—Mixtures of base-materials and additives the additives being macromolecular compounds only
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- C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
- C10M169/00—Lubricating compositions characterised by containing as components a mixture of at least two types of ingredient selected from base-materials, thickeners or additives, covered by the preceding groups, each of these compounds being essential
- C10M169/04—Mixtures of base-materials and additives
- C10M169/044—Mixtures of base-materials and additives the additives being a mixture of non-macromolecular and macromolecular compounds
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- C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
- C10M173/00—Lubricating compositions containing more than 10% water
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- A61L2400/00—Materials characterised by their function or physical properties
- A61L2400/10—Materials for lubricating medical devices
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- A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
- A61L2420/00—Materials or methods for coatings medical devices
- A61L2420/02—Methods for coating medical devices
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- A61L2420/00—Materials or methods for coatings medical devices
- A61L2420/06—Coatings containing a mixture of two or more compounds
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/18—Processes for applying liquids or other fluent materials performed by dipping
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
- B05D3/06—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation
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- C—CHEMISTRY; METALLURGY
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- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
- C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
- C08F220/04—Acids; Metal salts or ammonium salts thereof
- C08F220/06—Acrylic acid; Methacrylic acid; Metal salts or ammonium salts thereof
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- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
- C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
- C08F220/10—Esters
- C08F220/26—Esters containing oxygen in addition to the carboxy oxygen
- C08F220/28—Esters containing oxygen in addition to the carboxy oxygen containing no aromatic rings in the alcohol moiety
- C08F220/285—Esters containing oxygen in addition to the carboxy oxygen containing no aromatic rings in the alcohol moiety and containing a polyether chain in the alcohol moiety
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- C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
- C10M2201/00—Inorganic compounds or elements as ingredients in lubricant compositions
- C10M2201/02—Water
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- C10M2207/021—Hydroxy compounds having hydroxy groups bound to acyclic or cycloaliphatic carbon atoms
- C10M2207/0215—Hydroxy compounds having hydroxy groups bound to acyclic or cycloaliphatic carbon atoms used as base material
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- C10M2209/062—Vinyl esters of saturated carboxylic or carbonic acids, e.g. vinyl acetate
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- C10N2050/015—Dispersions of solid lubricants
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- C10N2070/00—Specific manufacturing methods for lubricant compositions
Definitions
- This invention concerns coating solutions and methods of making them, methods of coating with such solutions and coatings formed from the solutions, and medical devices or other articles provided with such coatings, but especially medical devices intended to be inserted into the human or non-human animal body.
- the invention more specifically concerns coatings for medical devices comprising lubricious polymers so as to enhance the properties of the devices when in contact with the body.
- Lubricious coatings for medical devices are intended to facilitate insertion, manipulation, articulation and removal of the device.
- Typical such devices are catheters and other tubes.
- the elements of the invention which are the subject of this patent application include a method of making a coating solution, a coating solution made by the method, a coating solution in storage, a method of coating a substrate which is on, or is part of, a medical device or other article, a substrate, article or medical device having a coating so applied, a coated medical device packaged in a hydration solution, and a coated substrate, article or medical device wherein the coating has certain novel and advantageous features.
- the invention addresses improvements in coating solutions, with the object of providing one or more of various advantages, which may include a coating solution with an extended pot-life (meaning both the storage life and the usage life of the coating solution); avoiding the need to mix in a cross-linker just prior to the application of the solution to a device; reduced frequency of having to discard and replace the coating solution during production; reduced waste; ease of use; and a stable coating after having been cured on the device that can be stored in water for extended periods of time, enabling the production of ready-to-use pre-hydrated products.
- an extended pot-life meaning both the storage life and the usage life of the coating solution
- the method of making a coating solution includes the steps of polymerising an initial monomer feed comprising an N-vinyl pyrrolidone and an acrylate, preferably methacrylate, salt in water to synthesise a copolymer thereof, acidifying the resulting copolymer-water mixture to give free carboxylic acid groups along the copolymer backbone, diluting the aqueous solution down with alcohol, and adding a cross-linking agent which is capable of reacting with the carboxylic acid groups and curing the copolymer at a later stage after the coating solution has been applied to a substrate and the copolymer coated thereon.
- the invention provides that during the time between adding the cross-linking agent and putting the solution to further use by applying it to the substrate, the aqueous-alcoholic solution may be stored for an extended period, suitably for at least one month and desirably for substantially longer.
- acrylate here is used in its broad sense to mean substituted as well as unsubstituted derivatives of acrylic acid.
- acrylate monomer salts that may be included for co-polymerisation with the selected N-vinyl pyrrolidone species are the salts of acrylic acid, methacrylic acid, 2-carboxyethyl acrylate, 2-carboxyethyl methacrylate, methacryloyl-L-lysine, mono-2-(methacryloyloxy)ethyl maleate.
- acrylate salts are barium methacrylate, lithium methacrylate, magnesium acrylate, sodium acrylate, zinc (di)methacrylate, sodium methacrylate, zinc acrylate, zirconium acrylate, potassium acrylate.
- Other salts include 3-sulfopropyl acrylate potassium salt, 3-sulfopropyl methacrylate sodium salt.
- suitable cations for the acrylate salts include lithium, sodium, potassium, magnesium, barium, and zinc, sodium being most generally preferred.
- Protected acrylic acids namely acrylic anhydride, methacrylic anhydride, may also be included as co-monomers.
- the initial monomer feed may specifically comprise from about 3 to 35% by weight, and preferably about 5 to about 25% by weight, of acrylate salt, based on the total monomer contert, to yield a suitable acid contert for the cross-linker to react with and stabilise the coating, without overly prejudicing the viscosity of the solution.
- the acrylate salt is taken to be a sodium salt.
- the monomer species in the monomer feed may comprise solely an N-vinyl pyrrolidone, usually unsubstituted N-vinyl pyrrolidone and in many cases specifically 1-vinyl-2-pyrrolidone, and an acrylate, preferably methacrylate, salt
- the copolymer may also include minor proportions of additional monomer species compatible with the storage and coating benefits of the invention. Any such additional monomer species should also be included in the initial monomer feed.
- Such additional co-monomers may include vinyl acetate (to aid coating adhesion), acrylamide (to aid lubricity), glycerol methacrylate (to increase hydrophilicity), 2-hydroxethyl methacrylate (to increase hydrophilicity), methoxy polyethylene glycol methacrylate (to increase lubricity and flexibility), polyethylene glycol methacrylate (to increase lubricity and flexibility), 2-methacryloyloxyethyl phosphorylcholine (to increase hydrophilicity).
- Zwitterionic co-monomers include [2-(methacryloyloxy)ethyl]dimethyl-(3-sulfopropyl)ammonium hydroxide, 2-((2-(methacryloyloxy)ethyl)dimethylammonio)ethyl 2-methoxyethyl phosphate, and 2-((2-(methacryloyloxy)propyl)dimethylammonio)ethyl 2-methoxyethyl phosphate.
- Any additional monomers should not amount to more than 50% by weight of the total monomer mixture, and preferably not more than 40% by weight.
- the co-polymerisation of the monomers is carried out under standard conditions, using a suitable initiator such as a radical initiator like an azo or peroxide initiator, which may be initiated by thermal (heat) or photo (UV or visible) initiation, as known in the art.
- a suitable initiator such as a radical initiator like an azo or peroxide initiator, which may be initiated by thermal (heat) or photo (UV or visible) initiation, as known in the art.
- the copolymer-water mixture is desirably purified by removal of unreacted monomer and low molecular weight components below, for example, 10,000 g mol ⁇ 1 .
- the solution may be dialysed, or precipitated, to remove some, or substantially all, such low molecular weight species.
- the removal of unreacted monomer, oligomer and salts can be controlled by the molecular weight cut-off (MWCO) of the membrane used to carry out the dialysis.
- MWCO molecular weight cut-off
- a 12-14,000 g mol ⁇ 1 MWCO membrane can be used to suitably remove species below 10,000 g mol ⁇ 1 .
- the pH of the solution is desirably about 4.5 or lower, typically in the range of 3 to 4.5.
- a pH greater than 3.5 or 4.0 within this overall range could be acceptable, as could a pH of less than 4.0 or 3.5.
- the aqueous mixture suitably has a copolymer concentration of at least about 4% and less than about 12%, preferably 5.0% or greater, and preferably 7.5% or less, all by weight.
- the step of diluting the aqueous copolymer solution down with alcohol is then carried out so that the diluted solution comprises typically 1 part copolymer-water mixture to 1-6 parts, typically 2-4 parts, e.g. 3 parts, of alcohol. These relative proportions may be measured by weight, or may more conveniently be measured by volume.
- the alcohol may be isopropyl alcohol (IPA, 2-propanol) or other lower alkanol, for example a C1 to C5 alkanol, such as methanol, ethanol, propanol (1-propanol) or butanol (1-butanol, 2-butanol, tert-butanol), pentanol or mixtures thereof.
- IPA isopropyl alcohol
- Other water and/or alcohol miscible solvents may be present in minor proportions in the final coating solution.
- the cross-linking agent may be selected from among many that are commercially available, and is preferably a multifunctional carbodiimide, or polycarbodiimide (that is, one having at least two reactive functional carbodiimide groups per molecule) which selectively reacts with carboxylic acid groups. Or it may be a multifunctional aziridine, or polyaziridine (that is, one having at least two reactive functional aziridine groups per molecule).
- This cross-linker enhances coating stability on the surface of a coated device.
- the preferred cross-linking agents compared with alternatives such as isocyanates, are less sensitive to the presence of water and are able to achieve long pot-life times. Their reactivity means they can be heat-cured using a standard oven.
- the balance between the concentration of the aqueous copolymer (more specifically the free acid contert) and the amount of cross-linker added should be such that a stable durable coating is achieved after subsequently coating an article and curing the coating thereon, whilst still maintaining an extended pot-life, meaning that the solution does not gel too quickly in storage before use. For example, if too much cross-linker is added, the coating will be extremely stable, but the coating solution will gel within a few days. Similarly, if the concentration of the aqueous polymer (free acid contert) is too high, then again a stable coating will be afforded, but the pot-life will be significantly reduced (will become too viscous to use). Therefore, it is important to maintain a balance. We have found that a concentration between 5.0 to 7.5% w/w for the aqueous copolymer works well (that is, 5.0 to 7.5% w/w of copolymer in water).
- the cross-linker would typically be added in an amount of between 5.0 and 50% by weight relative to the copolymer, more preferably between 10 and 40% by weight.
- the proportion of cross-linker to the free acid contert of the copolymer in each particular case will depend upon the specific cross-linker used.
- concentration of the aqueous copolymer solution and the cross-linker contert are accordingly managed so as to maintain the stability of the coating solution over an extended storage period while preserving the lubricity and adhesion (durability) of coatings deposited therefrom and cured after such storage.
- the solution preferably has a solids contert of from about 1.0 to about 10 weight percent. A preferred minimum is about 1.5 weight percent. A preferred maximum is about 5.0 weight percent.
- Additional method steps may include the addition of one or more further polymers to the aqueous-alcoholic copolymer mixture.
- These further polymers may be used to improve the film-forming properties and the overall coating stability.
- Such further polymers may include hydrophilic polyurethanes, e.g. polyether-based hydrophilic polyurethanes, examples of which are available commercially, and can be formulated in suitable solvents, such as water and isopropyl alcohol or other suitable solvents e.g.
- C1-05 alkanols including methanol, ethanol, propanol (for example 1-propanol, 2-propanol), butanol (for example 1-butanol, 2-butanol, tert-butanol), pentanol, and other water and/or alcohol miscible solvents, or mixtures thereof, such as 2-butanone, tetrahydrofuran, tert-butyl methyl ether, 1-methyl-2-pyrrolidone.
- 2-butanone tetrahydrofuran
- tert-butyl methyl ether 1-methyl-2-pyrrolidone
- further polymer additions may also include hydrophilic polymers such as poly(vinyl pyrrolidone), poly(ethylene glycol), poly(acrylamide), poly(vinyl alcohol), hyaluronic acid, poly(methyl vinyl ether), poly(methyl vinyl ether-alt-maleic acid), poly(methyl vinyl ether-alt-maleic anhydride), poly(acrylic acid), poly(N-vinyl pyrrolidone-co-4-benzoylphenyl methacrylate-co-methoxy polyethylene glycol methacrylate-co-butyl methacrylate) or any selection of mixtures thereof.
- These further polymers may be used to improve the lubricity and dry-out time of the coatings.
- Other cured coating properties that can be adjusted by the use of additional polymers in the coating solution include flexibility, durability, adhesion, compatibility, and colour, amongst others.
- the aqueous-alcoholic coating solution afforded by the invention accordingly comprises a poly(N-vinyl pyrrolidone-co-acrylic, preferably methacrylic, acid) together with an effective proportion of a cross-linking agent, particularly a multifunctional carbodiimide, or polycarbodiimide, or multifunctional aziridine, or polyaziridine, it being noted that alternative species of N-vinyl pyrrolidones and alternative species of acrylates are envisaged.
- the alcohol contert of the solution assists in solubilising the cross-linker and aiding in the coating process, e.g. depositing the coating onto the substrate.
- the proportion of cross-linker added to the aqueous-alcoholic copolymer solution will depend on a number of factors, including the concentration of copolymer—the higher the concentration, the lower the amount of cross-linker required.
- a hydrophilic polyurethane may typically be included in a weight proportion of about 1 part polyurethane to between 1.5 and 3 parts copolymer, more frequently 1.7 parts or more, or 2.5 parts or less, of copolymer per part of polyurethane, both dissolved in aqueous-alcoholic solution.
- the further hydrophilic polyurethane may be present at an equal weight to four times the weight of the cross-linker, or from more than 1.5 times, or up to 3 times, the weight of the cross-linker.
- a preferred coating solution contains the various components within the following ranges of percentages by weight:
- Such components may include physical modifiers, for example wetting agents to enhance coating characteristics, as well as chemical modifiers and antimicrobial agents.
- the invention provides that during the time between adding the cross-linking agent and putting the solution to further use by applying it to the substrate, the aqueous-alcoholic solution may be stored in a closed vessel, suitably for at least one month (30 days) and desirably for six months or more. During this period, and subject to appropriate protection from elevated temperatures, the solution remains usable for coating purposes.
- Suitable storage vessels may be of plastic such as high density polyethylene or polypropylene, and/or glass bottles and/or stainless steel or other containers, jerrycans, drums, typically containing from 1 L to 25 L of coating solution.
- the solution is desirably not exposed to temperatures above 40° C. for continuous periods longer than 7 days. Accordingly, the invention provides a coating solution, made by the methods of the invention, which has the property of remaining usable for applying coatings, without further adjustment, after storage in a closed vessel for at least 30 days at a temperature not exceeding 40° C.
- the method of coating a substrate comprises applying a coating solution according to the invention to a substrate, evaporating the solution to leave an uncured polymer coating thereon, and curing the coating on to the substrate.
- Curing comprises cross-linking the copolymer, and is suitably achieved with heating, suitably in an oven or by microwave radiation, to an elevated temperature, for example between 40 and 100 degrees Celsius, usually between 60 and 80° C., for a suitable length of time, such as 0.25 to 5 hours, preferably 0.5 to 1.5 hours.
- the curing time of a coating is related to temperature, so that many coatings can be cured in under 15 minutes if a temperature greater than 90° C. is employed.
- the main constraint is the underlying medical device itself and what maximum temperature it can withstand without damage, such as deforming or warping for example. Fast curing times are beneficial because production times can be reduced, so throughput can be increased.
- the substrate may be a surface of a medical device, and may be the whole surface of the medical device.
- Devices include Foley catheters (latex, poly(urethane) and silicone), intermittert (urological) catheters (PVC and latex), PTCA (percutaneous transluminal coronary angioplasty) catheters, balloon catheters endotracheal tubes, rectal catheters, rectal cones, endoscopes, drainage catheters, dilators, introducer sheaths, intraocular lens inserters, tracheal dilators, cannulas, needles, orthopaedic implants and guidewires.
- the coating may be applied by standard techniques including dipping, spraying, painting, wiping, and rolling.
- Coated devices in accordance with the invention may be stored in hydration media including water or saline or other solutions, such as cleaning, disinfecting, antimicrobial or antibacterial solutions, for extended periods, making them especially suitable for ready-to-use and multi-use products including urological catheters. Accordingly, the invention extends to a packaged device having a lubricious coating in accordance with the invention stored in a hydration medium.
- the packaging may be selected from any packaging acceptable for containing the hydration medium and suitable for the device concerned. The device will normally be sealed into the packaging until it is required for use. Suitable packaging may include bags, pouches, foils, sleeves, envelopes, trays, sheaths, bottles, tubes, cartons and films.
- Medical devices to which the coatings of the invention are intended to be applied are normally required to be sterile when they are used. Accordingly, the practice of the invention may include a sterilisation step.
- a coated device stored in a hydration medium should be sterile.
- Numerous means of sterilisation are known for use with medical devices; among those preferred for use with this invention are ethylene oxide sterilisation techniques, and gamma and electron beam irradiation.
- Examples 1 to 3 highlight the synthesis of the base polymer. They highlight the inclusion of additional monomer species, which are compatible with the storage and coating benefits of the invention. They also show a possible purification method, e.g. dialysis, and the typical concentrations obtained after acidifying and purifying.
- This example demonstrates the synthesis of the base polymer.
- NVP N-vinyl pyrrolidone
- water 100 g
- sodium acrylate 3 g
- the mixture was heated to 70° C. whilst being purged with N 2 .
- AMBN 2,2′-azobis(2-methylbutanenitrile) (AMBN) (0.1 g) (dissolved in 1 g of NVP) was added in one portion to initiate the polymerisation.
- the polymerisation was carried out for 100 minutes, after which time water (100 g) containing HCl (50%) (4.5 mL) was added to quench the reaction and acidify the resulting copolymer-water mixture, thereby providing free carboxylic acid groups along the copolymer backbone.
- the mixture was allowed to stir and cool and was then purified by membrane dialysis against water ( ⁇ 10 L), using a molecular weight cut-off (MWCO) of 12-14,000 g mol ⁇ 1 , for approximately 16 hours.
- MWCO molecular weight cut-off
- the final co-polymer solution had a concentration of 6.4% w/w and a pH of 4.4, thus indicating that the copolymer-water mixture was successfully acidified.
- This example demonstrates the synthesis of the base polymer.
- the mixture was allowed to stir and cool and was then purified by membrane dialysis against water ( ⁇ 10 L), using a molecular weight cut-off (MWCO) of 12-14,000 g mol ⁇ 1 , for approximately 16 hours. Following dialysis, the final co-polymer solution had a concentration of 6.1% w/w and a pH of 4.5, thus indicating that the copolymer-water mixture was successfully acidified.
- MWCO molecular weight cut-off
- This example demonstrates the synthesis of the base polymer, including an additional monomer.
- NVP NVP
- water 100 g
- sodium methacrylate 3 g
- methoxy poly(ethylene glycol) methacrylate MPEGMA
- the reaction was carried out for 100 minutes, after which time water (100 g) containing HCl (50%) (4.5 mL) was added to quench the reaction and acidify the resulting copolymer-water mixture, thereby providing free carboxylic acid groups along the copolymer backbone.
- the mixture was allowed to stir and cool and was then purified by membrane dialysis against water ( ⁇ 10 L), using a molecular weight cut-off (MWCO) of 12-14,000 g mol ⁇ 1 , for approximately 16 hours.
- MWCO molecular weight cut-off
- the final co-polymer solution had a concentration of 6.8% w/w and a pH of 4.5, thus indicating that the copolymer-water mixture was successfully acidified.
- Examples 4 to 6 highlight how the polymers are formulated (mixed) with the cross-linker. Two types of cross-linker are given, multifunctional carbodiimide and multifunctional aziridine. Example 6 shows how the polymer can be formulated without cross-linker, which has been included to highlight the cross-linker requirement, i.e. that the coating is not stable (durable) if no cross-linker is added to the formulation.
- This example demonstrates how the base polymer is mixed with a carbodiimide cross-linker.
- the co-polymer solution prepared in Example 2 (20 g) was mixed with isopropyl alcohol (IPA) (60 mL) and stirred until homogenous. To this was added multifunctional polycarbodiimide cross-linker (0.4 g) and the solution was stirred until the cross-linker had dissolved ( ⁇ 30 minutes). The concentration of the solution was 2.0% w/w.
- IPA isopropyl alcohol
- This example demonstrates how the base polymer is mixed with an aziridine cross-linker.
- the co-polymer solution prepared in Example 2 (20 g) was mixed with IPA (60 mL) and stirred until homogenous. To this was added trimethylolpropane tris(2-methyl-1-aziridine propionate) (0.3 g) and the solution was stirred until the cross-linker had dissolved ( ⁇ 30 minutes). The concentration of the solution was 1.9% w/w.
- This example demonstrates how the base polymer is mixed with alcohol (no cross-linker).
- the co-polymer solution prepared in Example 2 (20 g) was mixed with IPA (60 mL) and stirred until homogenous. The concentration of the solution was 1.5% w/w.
- Examples 7 to 8 highlight the additional method step of adding one or more further polymers to the mixture, e.g. polyether-based hydrophilic and thermoplastic polyurethanes, which may be used to improve film-forming properties on certain substrates, thereby expanding the scope of materials that can be coated.
- further polymers e.g. polyether-based hydrophilic and thermoplastic polyurethanes, which may be used to improve film-forming properties on certain substrates, thereby expanding the scope of materials that can be coated.
- This example demonstrates how the additional polymer is formulated (added) to the base polymer formulation to provide a coating with enhanced film forming qualities.
- Hydromed D640 (0.75 g) was dissolved in a mixture of IPA/water (50 mU6.25 mL). To this was added the co-polymer prepared in Example 2 (25 g) and the solution was mixed until homogenous ( ⁇ 30 minutes). Separately, multifunctional polycarbodiimide cross-linker (0.375 g) was dissolved in IPA (43.75 mL) and the mixture was added to the polymer solution and stirred for 2 hours. The final concentration of the solution was 2.5% w/w.
- This example demonstrates how the additional polymer is formulated (added) to the base polymer formulation to provide a coating with enhanced film forming qualities.
- HydroSlip C (0.10 g) was dissolved in a mixture of IPA/water (10 mU1.25 mL). To this was added the co-polymer prepared in Example 2 (5 g) and the solution was mixed until homogenous ( ⁇ 30 minutes). Separately, multifunctional polycarbodiimide cross-linker (0.075 g) was dissolved in IPA (8.75 mL) and the mixture was added to the polymer solution and stirred for 2 hours. The final concentration of the solution was 2.3% w/w.
- Examples 9 to 11 highlight further polymer additions that may include hydrophilic polymers, which may be used to improve the lubricity and dry-out time of the coatings.
- Hydromed D640 (0.75 g) was dissolved in a mixture of IPA/water (50 mU6.25 mL). To this was added the co-polymer prepared in Example 2 (25 g) and the solution was mixed until homogeneous ( ⁇ 30 minutes). Separately, poly(vinyl pyrrolidone) (PVP) (0.75 g) was dissolved in IPA (32 mL). Once dissolved, this was added to the polymer solution previously prepared and mixed until homogenous.
- the cross-linker solution was prepared by dissolving multifunctional carbodiimide cross-linker (0.375 g) in IPA (11.75 mL). This was then added to the polymer mixture. The final solution was stirred for 2 hours. The concentration was 3.2% w/w.
- Hydromed D640 (0.75 g) was dissolved in a mixture of IPA/water (50 mU6.25 mL). To this was added the co-polymer prepared in Example 2 (25 g) and the solution was mixed until homogeneous ( ⁇ 30 minutes). Separately, poly(ethylene glycol) (PEG) (0.5 g) was dissolved in IPA (32 mL). Once dissolved, this was added to the polymer solution previously prepared and mixed until homogenous.
- the cross-linker solution was prepared by dissolving multifunctional carbodiimide cross-linker (0.375 g) in IPA (11.75 mL) and then adding this to the polymer mixture. The final solution was stirred for 2 hours. The concentration was 3.0% w/w.
- a 0.6% w/v solution of hyaluronic acid sodium salt (HA) was prepared by dissolving HA (0.6 g) in water (100 g).
- the co-polymer solution prepared in Example 2 (4 g) was combined with water (3 g) and the HA solution (3 g).
- IPA 14 mL was added to this mixture dropwise under stirring such that a clear solution resulted.
- Hydromed D640 (0.15 g) was then dissolved in this mixture.
- the multifunctional carbodiimide cross-linker 0.057 g was dissolved in IPA (1 mL) and then added to the coating solution. The solution was stirred for 2 hours.
- the concentration of the coating solution was 2.0% w/w.
- Examples 12 to 15 highlight how the polymers/formulations prepared in the previous examples are coated onto various substrates/medical devices using various techniques, such as dipping or wiping and how they are cured using various temperatures/times.
- Example 4 This example demonstrates how the coating formulation prepared in Example 4 can be applied to a particular substrate/device and how it can be cured at a particular temperature for a particular period of time.
- PVC Intermittert Catheters were first cleaned by wiping with an IPA soaked lint-free cloth. Once dry, they were dipped into the coating solution prepared in Example 4 and submerged for approximately 10 seconds. After this time, they were extracted and allowed to dry under ambient conditions for at least 10 minutes. They were then transferred to an oven and heated at 70° C. for 1 hour to cure the coating. The samples were allowed to cool before being packaged.
- This example demonstrates how the coating formulation prepared in Example 6 (without cross-linker) can be applied to a particular substrate/device and how it can be heated at a particular temperature for a particular period of time. This example is included as a comparison to show the difference between a coating formulated with cross-linker and a coating formulated without cross-linker.
- PVC Intermittert Catheters were first cleaned by wiping with an IPA soaked lint-free cloth. Once dry, they were dipped into the coating solution prepared in Example 6 and submerged for approximately 10 seconds. After this time, they were extracted and allowed to dry under ambient conditions for at least 10 minutes. They were then transferred to an oven and heated at 70° C. for 1 hour. The samples were allowed to cool before being packaged.
- Example 7 This example demonstrates how the coating formulation prepared in Example 7 can be applied to a more challenging substrate through incorporation of an additional polyether-based polyurethane, which serves to improve the film-forming properties of the coating.
- Silicone Foley Catheters were first cleaned by wiping with an IPA soaked lint-free cloth. Once dry, they were dipped into the coating solution prepared in Example 7 and submerged for approximately 15 seconds. After this time, they were extracted and allowed to dry under ambient conditions for at least 10 minutes. They were then transferred to an oven and heated at 70° C. for 1 hour to cure the coating. The samples were allowed to cool before being packaged.
- Example 9 This example demonstrates how the coating formulation prepared in Example 9 can be applied to a particular substrate/device and how it can be cured at a particular temperature for a particular period of time.
- PVC Intermittert Catheters were first cleaned by wiping with an IPA soaked lint-free cloth. Once dry, they were dipped into the coating solution prepared in Example 9 and submerged for approximately 10 seconds. After this time, they were extracted and allowed to dry under ambient conditions for at least 10 minutes. They were then transferred to an oven and heated at 70° C. for 45 minutes to cure the coating. The samples were allowed to cool before being packaged.
- Example 11 This example demonstrates how the coating formulation prepared in Example 11 can be applied to a particular substrate/device and how it can be cured at a particular temperature for a particular period of time.
- Poly(urethane) catheters were first cleaned by wiping with an IPA soaked lint-free cloth. Once dry, they were dipped into the coating solution prepared in Example 11 and submerged for approximately 10 seconds. After this time, they were extracted and allowed to dry under ambient conditions for at least 10 minutes. They were then transferred to an oven and heated at 70° C. for 45 minutes to cure the coating. The samples were allowed to cool before being packaged.
- Example 9 This example demonstrates how the coating formulation prepared in Example 9 can be applied to a particular substrate/device and how it can be cured at a particular temperature for a particular period of time.
- Poly(amide) PTCA catheters were first cleaned by wiping with an IPA soaked lint-free cloth. Once dry, they were wipe coated using the solution prepared in Example 9 and allowed to dry under ambient conditions for at least 10 minutes. They were then transferred to an oven and heated at 65° C. for 1.5 hours to cure the coating. The samples were allowed to cool before being packaged.
- Example 9 This example demonstrates how the coating formulation prepared in Example 9 can be applied to a particular substrate/device and how it can be cured at a particular temperature for a particular period of time.
- Thermoplastic elastomer (TPE) based catheters was first cleaned by wiping with an IPA soaked lint-free cloth. Once dry, they were dipped into the coating solution prepared in Example 9 and submerged for approximately 10 seconds. After this time, they were extracted and allowed to dry under ambient conditions for at least 10 minutes. They were then transferred to an oven and heated at 95° C. for 8 minutes to cure the coating. The samples were allowed to cool before being packaged.
- TPE Thermoplastic elastomer
- Examples 19 to 25 demonstrate the properties/functionality of the coated devices prepared in previous examples, such as reduced friction (increased lubricity), coating stability (durability), and increased dry-out time.
- Example 12 The PVC catheters coated in Example 12 were evaluated for their coating uniformity using crystal violet dye, their lubricity after hydration in water for 20 seconds and coating durability using a wet glove test and subsequent dye. In all cases the coating was uniform, lubricious and durable under the test conditions employed. The coating demonstrated a dry-out time of approximately 3 minutes and a coefficient of friction below 0.3.
- Example 13 The PVC catheters coated in Example 13 were evaluated for their coating uniformity using crystal violet dye, their lubricity after hydration in water for 20 seconds and coating durability using a wet glove test and subsequent dye. The uniformity and initial lubricity were adequate, however under mild abrasion the coating was easily removed from the surface of the catheter. Thus indicating the necessity for cross-linker to be added to the formulation.
- Example 14 The silicone catheters coated in Example 14 were evaluated for their coating uniformity using crystal violet dye, their lubricity after hydration in water for 20 seconds and coating durability using a wet glove test and subsequent dye. In all cases the coating was uniform, lubricious and durable under the test conditions employed.
- the PVC catheters coated in Example 15 were evaluated for their coating uniformity using crystal violet dye, their lubricity after hydration in water for 20 seconds and coating durability using a wet glove test and subsequent dye. In all cases the coating was uniform, lubricious and durable under the test conditions employed. The coating demonstrated a dry-out time of approximately 6 minutes, i.e. twice as long as that shown by coated Example 12, as a result of the PVP inclusion. The coefficient of friction was typically below 0.2. Also, a cure time of 45 minutes was sufficient to provide the desired coating properties.
- Example 16 The poly(urethane) catheters coated in Example 16 were evaluated for their coating uniformity using crystal violet dye, their lubricity after hydration in water for 20 seconds and coating durability using a wet glove test and subsequent dye. In all cases the coating was uniform, lubricious and durable under the test conditions employed. It was noted that the lubricity had increased in comparison with coated Example 12 as a results of the HA inclusion. The coefficient of friction was typically below 0.2. Also, a cure time of 45 minutes was sufficient to provide the desired coating properties.
- Example 17 The poly(amide) catheters coated in Example 17 were evaluated for their coating uniformity using crystal violet dye, their lubricity after hydration in water for 20 seconds and coating durability using a wet glove test and subsequent dye. In all cases the coating was uniform, lubricious and durable under the test conditions employed.
- the TPE catheters coated in Example 18 were evaluated for their coating uniformity using crystal violet dye, their lubricity after hydration in water for 20 seconds and coating durability using a wet glove test and subsequent dye. In all cases the coating was uniform, lubricious and durable under the test conditions employed. Surprisingly, it was noted that the quality of the coating was akin to that achieved in coated Example 15, thereby highlighting that the desired coating properties can be achieved after a shorter curing period (8 minutes), when a higher cure temperature is employed.
- Examples 26 to 27 demonstrate the increased pot-life of the coating formulations prepared in previous examples and include details of storage conditions, testing (e.g. viscosity), device coating and functional testing.
- This example shows the comparative testing results for the formulation prepared in Example 7 tested on day 1 and after 9 months storage at ambient temperature.
- This example shows the comparative testing results for the formulation prepared in Example 9 tested on day 1 and after 6 months storage at ambient temperature.
- Example 28 demonstrates sterilisation (by ethylene oxide) and subsequent biocompatibility testing of a device coated with a formulation of the invention.
- a coating formulation was prepared according to a similar procedure as that described in Example 9.
- PVC Intermittert Catheters were then coated according to a similar procedure as that described in Example 15.
- the coated samples were sterilised by ethylene oxide (EtO) gas and then tested according to IS010993, whereby the cytotoxicity, irritation, acute systemic toxicity and sensitisation effects of the coated article were evaluated.
- the coating was considered non-cytotoxic to the subconfluent monolayer of L-929 mouse fibroblast cells and non-irritant to the skin of New Zealand White Rabbits. It was also demonstrated that the coating did not reveal any systemic toxicity when administered to Swiss Albino mice and was non-sensitising to the skin of Guinea pigs under the experimental conditions and doses employed.
- Example 29 demonstrates the stability of the coating when a coated device is left submerged in water for an extended period of time, i.e. the functionality is unaltered after this period. This is to exemplify the potertial for this coating to be utilised on ready-to-use (pre-hydrated) products.
- a coating formulation was prepared according to a similar procedure as that described in Example 7.
- PVC Intermittert Catheters were then coated according to a similar procedure as that described in Example 15.
- Coated catheters were tested on day 1 and demonstrated a uniform, lubricious and stable (durable) coating.
- the coated catheters were then incubated in a sealed tube containing water at ambient temperature and tested periodically to determine the long-term stability of the coating.
- This example demonstrates that the dry-out time of the coating can be extended further by hydrating the coating for longer periods of time, e.g. 24 hours. This may be particularly advantageous for ready-to-use products supplied in water or saline, for example.
- a coating formulation was prepared according to a similar procedure as that described in Example 9.
- PVC Intermittert Catheters were then coated according to a similar procedure as that described in Example 15.
- Coated catheters were tested on day 1 after being hydrated for 20 seconds.
- the coated catheters demonstrated a uniform, lubricious and stable (durable) coating, with a dry-out time of approximately 6 minutes.
- the coated catheters were then incubated in a sealed tube containing water at ambient temperature overnight ( ⁇ 16 hours) and re-tested.
- the dry-out time had doubled to approximately 12 minutes, whilst still maintaining a uniform, lubricious and durable coating.
- a period of extended hydration is advantageous for achieving an extended dry-out time with the coating of the invention and hence, may prove beneficial for ready-to-use (pre-hydrated) products.
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Abstract
Description
Poly(N-vinyl pyrrolidone-co-methacrylic acid) in water: | 15-30% |
Hydrophilic polyurethane: | 0.4-1.4% |
Isopropyl alcohol (IPA): | 60-80% |
Water: | 3-10% |
Hydrophilic polymer: | 0.2-5.0% |
Polycarbodiimide cross-linker: | 0.15-0.5% |
Time | Appearance | Concentration | Viscosity* |
Day 1 | Clear, colourless | 2.48% w/w | 18 seconds |
solution | |||
9 months | Clear, colourless | 2.57% w/w | 22 seconds |
solution | |||
*viscosity has been measured using a Zahn Cup No. 2, which measures the time taken for the solution to flow through an orifice and can be used as a measure of viscosity. The relevant standards for this test method are ASTM D1084 and ASTM D4212. |
Time | Appearance | Concentration | Viscosity* |
Day 1 | Clear, colourless | 3.23% w/w | 25 seconds |
solution | |||
6 months | Clear, colourless | 3.26% w/w | 31 seconds |
solution | |||
*viscosity has been measured using a Zahn Cup No. 2, which measures the time taken for the solution to flow through an orifice and can be used as a measure of viscosity. The relevant standards for this test method are ASTM D1084 and D4212. |
Duration of Incubation | Lubricious | Stable |
1 day | YES | YES |
6 months | YES | YES |
12 months | YES | YES |
18 months | YES | YES |
Claims (21)
Applications Claiming Priority (4)
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GB1520751.7 | 2015-11-24 | ||
GB1520751 | 2015-11-24 | ||
GBGB1520751.7A GB201520751D0 (en) | 2015-11-24 | 2015-11-24 | Coatings for medical devices |
PCT/GB2016/000209 WO2017089739A1 (en) | 2015-11-24 | 2016-11-24 | Coating solutions, coatings formed therefrom, and coated medical devices |
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US20180258363A1 US20180258363A1 (en) | 2018-09-13 |
US11441092B2 true US11441092B2 (en) | 2022-09-13 |
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US15/777,983 Active 2037-10-08 US11441092B2 (en) | 2015-11-24 | 2016-11-24 | Coating solutions, coatings formed therefrom, and coated medical devices |
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US (1) | US11441092B2 (en) |
EP (1) | EP3380596A1 (en) |
JP (1) | JP6893038B2 (en) |
CN (1) | CN108603136B (en) |
AU (1) | AU2016361081B2 (en) |
BR (1) | BR112018010625B1 (en) |
CA (1) | CA3006161C (en) |
GB (1) | GB201520751D0 (en) |
WO (1) | WO2017089739A1 (en) |
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EP3643758A1 (en) * | 2018-10-25 | 2020-04-29 | BIOTRONIK SE & Co. KG | Silicone material with modified surface to improve sliding and frictional properties |
CA3120635A1 (en) * | 2018-11-21 | 2020-05-28 | Hollister Incorporated | Hydration solutions containing volatile solutes and medical device products including the same |
CN113692429B (en) * | 2019-02-15 | 2023-08-04 | 敏锐聚合物有限公司 | Biocompatible polymer coating containing therapeutic agents |
JP2020174937A (en) * | 2019-04-19 | 2020-10-29 | 東洋インキScホールディングス株式会社 | Medical instrument treatment agent and medical instrument comprising the same |
JP2022553294A (en) * | 2019-10-21 | 2022-12-22 | バイオコート、インコーポレイテッド | UV curable coating for medical devices |
CN111592856B (en) * | 2020-05-08 | 2022-08-05 | 南京普莱斯医疗器材有限公司 | Visual field clearing agent for medical endoscope and preparation method thereof |
KR102414787B1 (en) * | 2020-10-06 | 2022-07-01 | 숭실대학교산학협력단 | Biocompatible double layered coating composition and manufacturing method thereof |
CN113908345A (en) * | 2021-10-11 | 2022-01-11 | 浙江海圣医疗器械股份有限公司 | Preparation method of super-smooth hydrophilic coating |
CN115089770A (en) * | 2022-07-21 | 2022-09-23 | 江苏康进医疗器材有限公司 | Anticoagulation lubricating coating and preparation method thereof |
CN116041595A (en) * | 2022-12-15 | 2023-05-02 | 苏州大学 | Thrombolytic coating agent, preparation method and application thereof |
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- 2016-11-24 CN CN201680079911.5A patent/CN108603136B/en active Active
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- 2016-11-24 WO PCT/GB2016/000209 patent/WO2017089739A1/en active Application Filing
- 2016-11-24 BR BR112018010625-9A patent/BR112018010625B1/en active IP Right Grant
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US20180258363A1 (en) | 2018-09-13 |
CA3006161A1 (en) | 2017-06-01 |
GB201520751D0 (en) | 2016-01-06 |
AU2016361081B2 (en) | 2021-01-28 |
JP2019501270A (en) | 2019-01-17 |
WO2017089739A1 (en) | 2017-06-01 |
JP6893038B2 (en) | 2021-06-23 |
BR112018010625A2 (en) | 2018-11-27 |
CA3006161C (en) | 2023-02-14 |
CN108603136B (en) | 2022-07-12 |
AU2016361081A1 (en) | 2018-07-12 |
CN108603136A (en) | 2018-09-28 |
BR112018010625B1 (en) | 2020-12-15 |
EP3380596A1 (en) | 2018-10-03 |
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